THERMOPLASTIC TECHNOLOGY IN ARCHITECTURAL RAILING...

THERMOPLASTIC TECHNOLOGYTHERMOPLASTIC TECHNOLOGY

IN ARCHITECTURAL RAILING SYSTEMSIN ARCHITECTURAL RAILING SYSTEMS

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This Online Learning Seminar is available through a professional courtesy provided

by:

AVCON1451 Rt. 37 West

Toms River, NJ 08755Telephone 1-800-24-AVCON

Fax 732-286-0526E-mail:[email protected]

Internet: http://www.AVCONRAIL.com

© 2004 AVCON. The material contained in this course was researched, assembled, and produced by AVCON and remains their property. Questions or concerns about the content of this course should be directed to the program instructor.

• About the Instructor • Seminar Discussion Forum

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Thermoplastic Technology in Construction

• About the Sponsor


Presented By: Klint Stanley, National Sales Manager

AVCONToms River, NJ 08755

Description: Course is designed to provide information on the use andapplication of Thermoplastics in architectural railing systems

AIA/CES Info: Provider No. J624 – Course No. AEC014; LUs – 1.0

MCE Info: Contact your respective governmental licensing & regulatoryagency.

Expiration date: May 15, 2005

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This program is registered with AIA/CES for continuing professional registration. As such, it does not include content that may bedeemed on construed to be an approval or endorsement by the AIA or AEC Daily Corporation of any material or construction or anymethod or manner of handling, using, distributing or dealing in any material or product. Question related to specific materials,methods and services should be directed to the program instructor.


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How to use this Online Learning Course

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• Read and review the material contained in this seminar.

• Each slide may contain additional Instructor comments. To view thesecomments, double-click on the icon. Then, click on the comment windowto scroll through the text.

• To view this presentation, use the previous/next keys on each slide or the upand down arrow keys on your keyboard.

• Within this course is a code word that you will be required to enter in order toproceed with the online examination. Please be sure to write down this codeword so that you have it available for the test.

• To receive a certificate indicating course completion, refer to the instructionsat the end of the seminar.

• For additional information and post-seminar assistance, click on any of thelogos and icons within a page or any of the links at the top of each page.


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Learning Objectives

At the end of this seminar, participants will have a better understanding of:

• Basic architectural railing design considerations

• Use of structural thermoplastic material in construction

• Design capabilities of structural thermoplastic in railing systems

• How to specify structural thermoplastic railing systems

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Structural Thermoplastic Technology

• Whether seeking which railing material to use in the design of a new buildingor replacing an existing system, several factors warrant consideration.

• First, and most basic, a strong system that meets national building codes isessential.

• Color and style are important items.

• Next decide if cost is the major factor. While wanting the best value, ifmaintenance costs are excessive and if replacement is frequent, then whatappears to be the cheapest rail, simply is not.

• Does the system we select meets structural codes when new, will it maintainthat strength over time?

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• For years one of the most problematic items of building maintenance has beenthe railing system used to protect its occupants.

• The condition of the railing is a major factor in the building's appearance andin potential liability. Railings must be constantly maintained and corrosion isan ever present enemy.

• Are there materials and systems that could postpone the inevitablereplacement?

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• Who of us, though, cannot remember the time when an item made of plasticwas not thought of as cheap. Now, however, some of the most expensiveproducts you can buy are made of plastics .

• But what about strength, can an "upscale appearance" using plastic railingbe maintained. Why, when safety is a paramount concern and the potentialfor liability is so excessive, would plastic be selected?

• It's because after a thorough investigation of thermoplastic technology,coupled with the most valuable test of all, "real and everyday use," thesuperior performance of structural thermoplastic railing has been proven.

• The educated design professional, after learning what can be done withtoday's technologically advanced structural plastic, will only specify anengineered thermoplastic. They are calling on the manufacturer formaintenance-free products.

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• Strength. The liability associated with any railing can be greatly reduced byspecifying and using a rail system that exceeds building codes, and, moreimportantly, maintains that strength over time.

• The natural corrosion and oxidation that occurs when screws and dissimilarmetals and materials, including concrete, are combined in the presence ofsalt and other chemicals will render many railing systems unsafe anddangerous.

• A railing that may have met code when installed, may not in a short periodof time. Without any compromise in safety, structural thermoplastic whenproperly fabricated can complement the aesthetic appeal of your design,eliminate maintenance, and keep the exceptional strength it is designedwith.

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• Plastics are NOT created equal. There are thousands of plastic recipes, knownin the industry as compounds. The right plastic for the right job is an industryin itself.

• Do not confuse knowledge of plumbing pipe and plastic patio furniture, gluedtogether, with the modern world of thermoplastic. After all you cannot useplastic sandwich wrap to side a house and you cannot use PVC plumbing pipeand fittings to build a structural railing system.

• The idea to use plumbing pipe with fittings (i.e., crosses, tees, elbows, etc.) isgreat if you want to run water through it, but it was never designed to bestructural.

• Enter into the equation a new family of plastics. You think nothing of all theselate model cars, with body side moldings and rocker panels in just about anycolor, and even high impact bumpers on the most expensive of cars.

• Special thermoplastics, designed with scientific polymers, compounds, andplastic alloys can provide materials that are non-corrosive, durable, attractive,and maintenance free.

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• Design professionals are learning fast that there is little need to specify metalswhen thermoplastics can meet their design criteria and in addition, offersubstantial savings in maintenance and replacement costs.

• Unlike some mechanical or component systems, thermoplastic railing can beshaped in the smoothest of radii or sharpest of bends. If you doubt thestrength, durability, and cosmetics of structural thermoplastic railing systems,take a trip to Walt Disney World, Six Flags, Universal, Holiday Inns, Sheraton,and many condominium projects just to name a few, and you will see majorexamples of structural "Plastic" railing at work in the most demanding ofsituations.

• So when you are considering what type of railing to use when building,designing, or replacing your railing, do not forget that you have an intelligentalternative...structural thermoplastics.

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What are Thermoplastics

• Thermoplastics are materials that are capable of softening or fusing whenheated and then returning to a rigid state when cooled.

• Thermoplastics come in a variety of types. Each type of material performsdifferently and has qualities that make it better suited for certain uses.The type of thermoplastic that is selected for use should depend on theapplication.

– An engine compartment may require a product that will performunder high mechanical and thermal loads.

– Products that are exposed to the environment may require a materialwith properties that include impact and weather resistance.

– Products that are used in laboratories or clean rooms may requirespecial qualities such as chemical or static resistance.

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Structural Thermoplastics in Construction

• Plastics have become common component in the building and constructionindustry.

• Several advantages of plastic over more traditional exterior building materialincluding reduced maintenance:

– Common problems with wood:• Moisture absorption.• Insects.• Require frequent repainting or staining.• Not permitted in many project types.

– Common problems with metals:• Rust.• Dents and scratches.• Costly maintenance.

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Engineering Grade Plastics

• The focus of this course will be on engineering grade plastics. EngineeringGrade plastics are all-purpose plastics and have uses that include; buildingconstruction, car manufacturing computer & TV monitors, compact disk cases,and packaging material just to name a few.

• Three common types of Engineering Grade plastics include:

– Polyvinyl Chloride (PVC).– Acrylonitrile/Butadiene/Styrene (ABS).– Acrylonitrile/Styrene/Acrylate (ASA).

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Engineering Grade Qualities

• PVC:

– Limited color stability in continuous exterior exposures in light colors; Nocolor stability in dark colors.

– Chalking.– Readily available, inexpensive product, good stiffness.– Good chemical resistance.

• ABS:

– Readily available product.– Easy to extrude or mold.– Lacks stiffness.– Limited color fastness.– Will become brittle after exposure to UV and environment.

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Engineering Grade Qualities

• ASA:

– High thermal stability.

• Dimensional stability.• Higher heat deflection point.

– Good Chemical Resistance.

– Resistance to weathering, aging and yellowing.

– Higher cost.

• Each of these types of engineering grade plastics also comes in a variety ofcomposites and blends formulated for specific uses.

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ASA Architectural Qualities

• There are a variety of material grades designed to meet a range of end useapplications by offering excellent:

– Weatherability.– Impact resistance.– Color retention.– Heat resistance.– Flammability.– Ease of processing.

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Weatherability

• ASA has high weathering resistance because the elastomer component iscomposed of an acrylate rubber. Compared with butadiene rubbers, e.g. asused in impact resistant polystyrene and ABS, it has significantly higherresistance to UV radiation and to attack by atmospheric oxygen.

• When plastics are exposed to outdoor weathering, it is not only theirmechanical properties which can change. The combination of UV radiation,atmospheric oxygen and heat often produces clearly visible yellowing too.

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Impact Resistance

• Testing is in accordance with ASTMStandards.

• This test shows how both productsstarted out with similar values, butonce exposed to the elements, ABSshows a steep, significant loss, whereASA maintains its properties overtime.

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Color Retention

• UV-Resistant ABS and PVC blends typically have a tendency to grey or yellowwhen exposed to UV or exterior exposure.

• ASA does not have the same tendency because the formulation of resins arespecifically designed for outdoor use and resisting UV rays.

• ASA has higher pigment concentration compared to ABS or other plastics.

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Heat Resistance

• Long Term heat exposure cancause weakening in manystyrenic plastics. Whenexposed for extended periodsof time to 90 degree Ftemperatures, the mechanicalstrength of the ABS productsdecrease.

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Processing – Extruding

• Resin (Plastic) in pellet or powder form is placedinto a hopper.

• It then feeds into an extruder chamber where thematerial is heated to the proper temperature, thenpushed through the machine by a large turningscrew-like mechanism.

• The material exits through a die specificallydesigned to give the plastic the required shape.

• The plastic then enters through a series of downstream equipment (Vacuum sizers and coolingtanks), which sizes it to the required tolerancesand cools the extrusion.

• At the end of the process the extrusion is cut tothe desired length and packaged for shipment.

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Processing – Co-Extrusion

• Co-Extrusion is the blending and extruding of two or more resins creating acap (outside) and a substrate (inside).– Two or more plastics are used.

• Co-Extruding creates a superior product when compared to the performanceof each individual resin.

• Benefits of co-extrusions include enhanced product performance and costeffectiveness.

Machining and fabricating of co-extruded tubing

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Processing – Injection Molding

• Resin is fed to the machine through the hopper. The resins enter the injectionbarrel by gravity though the feed throat. Upon entrance into the barrel, theresin is heated to the appropriate melting temperature.

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Processing – Injection Molding

• The mold is the part of the machine that receives the plastic and shapes itappropriately. The part is cooled to a temperature that allows the resin tosolidify and be cool to the touch. The mold plates are held together byhydraulic or mechanical force. The part is ejected from the mold andrepeated.

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Architectural Railing Design Basics

• Structural Design Issues:

– Steel reinforced thermoplastic railing systems should be designed to allowfor expansion and contraction.

– Railings are designed with an “Expansion Joint” in the top rail and aninternal color-coded sleeve.

– When the temperature is low and the product is in a contracted state, theexpansion joint will be open as designed and you will see the color codedexpansion sleeve.

– Basic mounting options include Flange Mount, Fascia Mount, Core Mountand Weld Mount.

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• Safety:

– To stop people from falling; toassist people on stairs, ramps, etc.

– Building codes published withcertain requirements on height,size and design, and strength.

– Member spacing – Current buildingcodes specify that a 4 inch spherenot be able to pass through anypart of the railing system.

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• Code Compliance:

– Structural Loads – Railing must be designed to meet or exceed structural load requirements of the prevailing code authority. Testing must be in accordance with ASTM Standards.

– ADA Compliance- Americans with Disabilities Act requires the diameter of the handgrip portion of the handrail, if round, to be not less than 1 inch or more than 1.5 inches. Certain states and municipalities may require a specific size within this range.

– ADA standards also list specific load and height requirements that railings and handrails must meet as well as clearance requirements on stairs, ramps, and landings.

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• Sizing and Dimension:

– Structural components of railings (posts and horizontal rails) are approximately 2 inches in diameter with a 5/16 inch wall thickness. Vertical balusters are 1 inch in diameter.

– Handrails are typically installed between 34 and 38 inches above finish grade. At 42 inch high guardrails, the handrail is attached to the vertical supports in a "floating application". Typical handrails are 1-1/2 inches in diameter to comply with ADA grasping requirements.

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• Installation Issues:

– Concrete: Railings can either be core mounted or flange mounted intoconcrete. Minimum depth recommended for a core mount is 4 inches intoa 4 inch diameter hole. Flange mount can be accomplished by utilizing thecorrect anchors. Minimum embedment is specified by anchor provider.

– Steel: Installation into steel can be accomplished in two ways. When it ispossible to drill a hole through the steel, a flange mount can be used witha bolt and nut application. Alternately, the steel within the post can beextended and welded to the steel.

– Wood: Either flange or fascia mounts may be used. 3/8 inch diameter lagbolts are recommended in both mounting applications. The length of thelag bolt is determined by the application. Proper “Blocking” is arequirement when mounting into wood. Usually a double 2x piece ofwood is sufficient.

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Architectural Railing Applications

• Commercial.

• Residential.

• Leisure/Entertainment.

• Municipal Facilities.

• Hotel/Motel.

• Condominium.

• Stadium.

• Amusement Parks.

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Architectural Railing Applications - Thermoplastic

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Limitations of Plastic Railing Assemblies

• Where not to use:

– Anywhere that code requires a non-combustible (Steel) rail.• Fire Exit Stairwells.

– Automotive Guardrail.• 10,000 pound point load resistance is required.

– Extremely ornate railings.• The costs involved in development of molds makes ornate railings not

cost effective.

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Please remember the word CO-EXTRUSION. You will be required to enter it inorder to proceed with the online examination.


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Specifying Structural Thermoplastic Railings

• Part 1 - General:– Reference Standards/Building Codes/ADA.– Structural/System Performance.– Shop Drawings/Test Reports.– Engineering and Certifications.

• Part 2 - Products:– Appropriate competitors.– Using the right materials for the job.– Performance criteria.– Shop fabrication.

• Part 3 - Execution:– Examine surface to receive railings.– Installation sequence.– Installation requirements.

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Architectural Railings Overview

• Use and application of railings.

– With safety being of utmost importance, railings are required to preventfalling off a structure and to provide assistance when using ramps or stairs.Typical applications include:

• Balconies and decks.

• Roof parapets.

• Stairs.

• Ramps.

• Retaining Walls.

• Surrounding Pools.

• Aesthetics.

• New polymer chemistry and technology is impacting how and wherethermoplastic railings can be used.

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• Available Railing Systems.

– Light Duty – Residential:

• Mechanical Aluminum (screwed together).

• PVC Porch Rail.

• Wrought Iron.

• Wood.

– Heavy Duty – Commercial:

• Welded Steel.

• Welded Aluminum.

• Steel Reinforced Thermoplastic.

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• Traditional Materials:

– Steel - Pro is strength; Con is rust and high maintenance cost.– Aluminum - Pro is design flexibility and powder coating color variety; Con

is oxidation, corrosion, and limited coating life.– Stainless Steel- Pros are strength and maintenance-freedom if the proper

grade is used; Cons are cost, no color selection, and rust if incorrect gradeis used.

– Wood - Pro is cost; Cons are deterioration and maintenance intensive.– Wrought Iron - Pro is design flexibility; Cons are rust and maintenance

intensive.

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• Thermoplastics.

– PVC:• Pros: strength and under certain conditions cost.• Cons: lack of color retention and weatherability.

– ASA:• Pros: weatherability and color retention.• Cons: cost, moderate stiffness.

– ABS:• Cons too flexible and brittle.

– ASA outer layer/PVC core:• Pros: good impact, stiffness, cost competitive, weatherability, and

color retention.

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Commonly Asked Questions

• Is Plastic Strong Enough?– Plastic Railing is engineered and designed to meet and exceed applicable

building codes. Independent testing supports this. Additionally, properlydesigned railing is a marriage between plastics and strategically placedmetal superstructures often creating structural strength far in excess ofconventional metal railing.

• Will plastic fade?– All materials such as paint or plastics will fade when subjected to certain

conditions such as ultra-violet light. Properly formulated plastics arecompounded so as not to be susceptible to fading. ASA (acrylics) arecommonly used in both paint and plastic formulations to stop fading.Plastics in the ASA family are vastly superior to others, such as PVC, in theareas or color retention and should be used when there will be exposureto UV light.

• Will plastic rust or corrode?– No. Plastics are used to eliminate rusting, painting and corrosion. Plastic

does not rust. Internal connectors are plastic or stainless steel.

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• Will thermoplastic get brittle in the sun, like PVC pipe?

– ASA is not susceptible to brittleness like PVC. ASA will not turn yellow orfade as does PVC.

• Will plastic scratch?

– Plastics, like other materials used in railing, is not indestructible. However,simple sanding and polishing can remove marks that may be forced into itssurface.

• Will plastic burn?

– Thermoplastics are self-extinguishing. An additional source of fuel isrequired to support combustion.

• Does plastic give off toxic fumes if burned?

– All materials will give off some fumes if burning. The smoke producedwhen railing is ignited is less toxic than that produced by burning wood.

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• Do chemicals affect plastic?– Some chemicals will affect any material known to man. Most chemicals that would

ever come in contact with railings will have little or no affect. This includes allcommon household and commercial cleaners. Additionally, no glues are used.Connections are all mechanical.

• How are plastic connections made?– Typically, a load bearing bracket/support is attached to one side of every joint. The

adjoining rail member is placed over on onto that support and secured in place witha stainless steel screw or pin.

• How are plastic railings mounted?– The typical methods of mounting metal or wood railing apply. Four basic and

common methods exist:• Using appropriate bolts or lags secured through a base plate attached to each

post.• Coring an appropriate size hole to insert each post into. Once inserted self-

expanding grout secures the rail in place.• Welding if the surface is metal.• Bolting to the side or structural stringer, commonly known as Fascia Mounting.

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• How are plastic railings mounted?– The typical methods of mounting metal or wood railing apply. Four basic

and common methods exist:• Using appropriate bolts or lags secured through a base plate attached

to each post.• Coring an appropriate size hole to insert each post into. Once inserted

self-expanding grout secures the rail in place.• Welding if the surface is metal.• Bolting to the side or structural stringer, commonly known as Fascia

Mounting.

• Is the color all the way through the material?– Yes.

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• Can you bend the tubing?

– Yes, tubing may be bent, twisted, and contorted to meet most designs.No molded “fittings” are used that would compromise strength or theability to form radii or other bends.

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Conclusion of This Module

• AEC Daily Corporation is a Registered provider with the AIA Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members.

• If you desire AIA/CES, CSI and/or state licensing continuing education credits, please click on the button below to commence your online examination. Upon successful (80% or better) completion of the exam, please print your Certificate of Completion.

• For additional knowledge and post-seminar assistance, please avail yourself to the Seminar Discussion Forum (click on the link above and bookmark it in your browser).

• If you have colleagues that might benefit from this seminar, please let them know. Last, revisit AEC Daily web site and download additional programs available at the Online Learning Center.

© 2004 AVCON. The material contained in this course was researched, assembled, and produced by AVCON and remains their property. Questions or concerns about the content of this course should be directed to the program instructor.

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